Sorting arrangement, in particular for items of post

ABSTRACT

A sorting apparatus is disclosed which includes a plurality of carriers which circulate from an upper section of a conveying device to a lower section of the conveying device. The carriers are secured to circulating carriages that are driven by an endless cable that circulates in the two planes, or between the upper and lower sections of the conveying device. The upper and lower sections are connected by a vertically running deflection device which includes one wheel that connects a rear side of the upper section of the conveying device to a front side of the lower section of the conveying device as the cable proceeds from the upper section to the lower section. The vertically running deflection device also includes a second wheel which connects a rear side of the lower section of the conveying device to a front side of the upper section of the conveying device as the cable returns from the lower section to the upper section of the conveying device. The wheels rotate on roller systems and further include rubber inserts for smooth and quiet operation. As the cable and conveying carriages are circulated between the upper and lower sections, the cable and conveying carriages are extended around one of the wheels and pass through the same wheel on the return trip.

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

The present invention relates generally to sorting apparatuses and, morespecifically, to sorting apparatuses for sorting mail and otherarticles. Still more specifically, the present invention relates to adual-level sorting apparatus which includes a conveying device having anupper section and a lower section, the upper and lower sections beingconnected so that mailpieces or articles can be circulated from theupper section to the lower section for sorting.

The machine-readable postcodes which should be specified on items ofmail, such as letters, postcards, packets and the like, as anidentification for a location, a postal district, a PO box or a majorrecipient, permit rapid, mechanical distribution of mail. In thisarrangement, sorting of the incoming items of mail takes place with theaid of controllable conveyable-article carriers which are each loaded,manually or mechanically, with an item of mail in special inputlocations and then discharge said item of mail to a sorting container,or a corresponding sorting compartment, assigned to the respectivepostcode. Since, for space-saving reasons, it is desired for both theinput locations and the sorting containers or sorting compartments to bearranged in various planes, the conveyable-item carriers circulating onconveying devices must, if appropriate, also be capable of spanningvarious levels. After transfer of the item of mail to the assignedsorting container or the assigned sorting compartment, the emptyconveyable-article carrier can once again be loaded with an item of mailwhen it passes an input location.

U.S. Pat. No. 3,300,026 discloses a sorting apparatus for mail which haspairs of conveyable-article carriers which circulate on a conveyingdevice and are intended for receiving, for transporting and fordischarging mail, in a controllable manner. The conveying devicecomprises two chains which circulate endlessly at a distance from oneanother and that are guided in a meandering fashion over correspondingrollers and, on a plurality of planes located one above the other. Thechains guide the conveyable-article carriers past in each case one rowwith sorting containers. The meandering progression of the conveyingdevice in a plurality of planes results in a relatively large overallheight of the sorting apparatus, with correspondingly poor accessibilityto the sorting containers arranged in the top planes.

WO 95/02468 discloses a sorting apparatus, in particular for mail, whichhas a plurality of conveyable-article carriers which circulate on aconveying device and are intended for receiving, for transporting andfor discharging, in a controllable manor, the conveyable articles toassigned sorting containers. The conveyable-article carriers arefastened on circulating transporting carriages of the conveying device,it being the case that the transporting carriages, which are driven byan endlessly circulating transporting cable, are guided, by way ofrollers, on two profiles which are aligned at a vertical distance fromone another and extend in the transporting direction. The transportingcarriages circulate, via a vertical deflection, in two planes, with theresult that, in each plane, they can be guided along in each case twoparallel rows with sorting containers.

In the case of the conveying device of the sorting apparatus disclosedby WO 95/02468, the conveyable-article carriers which are loaded withconveyable articles, for example, in a rear loading zone of the bottomplane, are deflected forwards on the same level and then transportedpast the sorting containers arranged in a row on the front side of thebottom plane. In the region of the vertical deflection, theconveyable-article carriers are then guided obliquely upwards into thetop plane and, there, are transported past the sorting containersarranged in a row on the rear side. In the region of the end side, thesorting containers are then deflected forwards on the same level andthen transported past the sorting containers arranged in a row on thefront side. In the region of the vertical deflection, theconveyable-article carriers are then guided obliquely downwards into thebottom plane and, there, are transported past the sorting containersarranged in a row on the rear side. In the region of the verticaldeflection, the two profiles for guiding the transporting carriages andthe transporting cable run, in one case, obliquely from bottom to topand, in another case, obliquely from top and to bottom in the oppositedirection. Guidance of the transporting cable over two appropriatelysized cable wheels arranged in the region of the vertical deflectionwould result in a greater overall length of the sorting apparatus.Guidance of the transporting cable over a plurality of deflectionrollers arranged in the region of the vertical deflection may avoid thisincrease in overall length. On the other hand, the service life of thetransporting cable is influenced to a great extent by the flexing of thecable which takes place as the cable runs over the deflection rollers.Moreover, aggravating running noise is produced when the transportingcable in guided over a plurality of deflection rollers.

SUMMARY OF THE INVENTION

The present invention has solved the problem of improving, for thesorting apparatus which is known from WO 95/02468, the guidance of thetransporting cable in the region of the vertical deflection, withoutincreasing the overall length in the process, in such a way as toincrease the service life of the transporting cable and to reduce therunning noise.

Besides sorting and distributing mail in public post offices or centralin-house mail departments of large companies, a sorting apparatusaccording to the invention may also be used for comparable tasks, forexample, in storage systems or automated order-picking systems, in thecase of which goods or parts provided with codings are fed to sortingcontainers, or sorting compartments, assigned to the respective codings.

The invention is based on the finding that the advantages in terms ofservice life and quiet running which can be achieved by guiding thetransporting cable over a large cable wheel can be combined with theadvantages in terms of low space requirements which can be achieved byguiding the transporting cable over a plurality of deflection rollers.For this purpose, the transporting cable is guided over a wheel rimwhich, with the omission of central mounting, has its innercircumference mounted rotatably on a plurality of supporting rollers.

In an embodiment, the present invention permits a further reduction inthe overall length of the sorting apparatus. The interengagement of thewheel rims results in a reduction in the order of magnitude of thewheel-rim diameter

In an embodiment, the present invention facilitates both theinstallation and the removal of the two inter-engaging wheel rims.

In an embodiment, the present invention provides for a considerableimprovement in terms of the quiet running of the sorting apparatus, inwhich case, wheel-rim inserts made of rubber in particular have provensuccessful.

In an embodiment, the present invention provides a sorting apparatuscomprising a conveying device including an upper section and a lowersection. The upper section and lower section are connected by atransport carriage which is connected to and propelled by an endlesscable. The transport carriage is also connected to a plurality ofarticle carriers whereby the transport carriage, endless cable andarticle carriers are circulated from the upper section to the lowersection of the conveying device. During the transition from the uppersection to the lower section, the endless cable extends around a firstwheel as the cable proceeds from the upper section to the lower section.On the return trip, or when the endless cable is returned from the lowersection to the upper section, the cable extends around a second wheel.Each of the wheels has an inner circumference that is rotatably mountedonto a plurality of supporting rollers.

In an embodiment, the first wheel extends through the second wheel.

In an embodiment, one of the wheels is separable so that one of the twowheels can be removed from the other of the two wheels.

In an embodiment, the wheels further comprise non-metallic inserts, suchas rubber, for engaging the cable.

In an embodiment, the upper and lower sections are disposed parallel toone another. Each section includes a front side disposed between firstand second opposing ends. Each section also includes a rear sidedisposed between first and second opposing ends. The front sides of theupper and lower sections are substantially coplanar as are the rearsides. The first wheel is disposed between the first ends of the upperand lower sections and extends from the rear side of the upper sectionto the front side of the lower section while the second wheel is alsodisposed between the first ends of the upper and lower sections andextends from the rear side of the lower section to the front side of theupper section.

In an embodiment, the path of the endless cable is as follows. Beginningfrom the second end of the upper section, the cable proceeds along therear side of the upper section to the first end of the upper section,around the first wheel to the first end of the lower section at thefront side of the lower section. The cable then proceeds along the frontside of the lower section to the second end of the lower section, aroundat least one deflection roller, or other means to propel the cable,which is disposed at the second end of the lower section. The cable thenproceeds to the rear side of the lower section from the second end ofthe lower section to the first end of the lower section. The cable thenproceeds around the second wheel to the front side of the upper sectionat the first end of front section, along the front side of the uppersection to the second end of the upper section and around at least onedeflection roller, or other means for propelling the cable, back to therear side of the upper section.

In an embodiment, the transport carriage comprises a plurality ofrollers and the upper and lower sections of the conveying device eachcomprise a tubular member that engages the rollers of the transportcarriage for smooth and quiet operation.

Other objects and advantages of the present invention will becomeapparent from reading the following detailed description and appendedclaims, and upon reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

An exemplary embodiment of the invention is described in more detailhereinbelow and is illustrated in the drawing, in which:

FIG. 1 is a perspective illustration of a conveyable-article carriercomprising a fixedly arranged wall part and a movably arranged wallpart,

FIG. 2 is the operating principle of a conveying device on whichconveyable-article carriers according to FIG. 1 circulate, said carriersbeing fastened on transporting carriages,

FIG. 3 is a perspective illustration of two modules, lined up side byside, of a sorting apparatus equipped with conveyable-article carriersaccording to FIG. 1 and with conveying device according to FIG. 2,

FIG. 4 is a side view of a sorting apparatus constructed from modulesaccording to FIG. 3,

FIG. 5 is a plan view of the sorting apparatus according to FIG. 4,

FIG. 6 is a perspective illustration of the guidance, over two planes,of the conveying device of the sorting apparatus illustrated in FIGS. 4and 5,

FIG. 7 is the vertical deflection of the conveying device illustrated inFIG. 6, with the schematically illustrated guidance of the transportingcable over two interengaging wheel rims,

FIG. 8 is a plan view of a wheel rim which has its inner circumferencemounted rotatably on a plurality of supporting rollers, and

FIG. 9 is a radial section through the wheel rim and a supporting rollerof the arrangement illustrated in FIG. 8.

It should be understood that the drawings are not necessarily to scaleand that the embodiments are sometimes illustrated by graphic symbols,phantom lines, diagrammatic representations and fragmentary views. Incertain instances, details which are not necessary for an understandingof the present invention or which render other details difficult toperceive may have been omitted. It should be understood, of course, thatthe invention is not necessarily limited to the particular embodimentsillustrated herein.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

FIG. 1 is a perspective illustration of a conveyable-article carrierwhich is designated as a whole by FT and comprises a fixedly arrangedwall part FW and a movable wall part BW. In this arrangement, themovable wall part BW can be pivoted about a pivot pin DA alignedtransversely with respect to the transporting direction TR of theconveyable-article carrier FT.

FIG. 1 illustrates the closed position of the conveyable-article carrierFT, in which the fixedly arranged wall part FW and the movably arrangedwall part BW, each of which are curved outward, form a cross-sectionallyapproximately V-shaped receiving pocket for the conveyable articles. Theclosed position is secured by a detent pawl SK which can be rotatedabout an axis designated by A and can be released by actuating asolenoid HM. If the detent pawl SK is released, then the movable wallpart BW is pivoted about the pivot pin DA such that an ejection alit,which is open at the bottom and belongs to the conveyable-articlecarrier FT, is formed. In this arrangement, the bottom extension of themovably arranged wall part BW forms an ejection chute AR which adjoinssaid ejection alit at the bottom and is inclined counter to thetransporting direction TR.

FIG. 3 shown a perspective illustration of two modules M1 and M2, linedup side by side, of a sorting apparatus equipped with conveyable-articlecarriers FT according to FIG. 1. In this arrangement, in each case atotal of five conveyable-article carriers FT are fitted on onetransporting carriage TW, the latter being a constituent part of aconveying device FE and circulating in two planes E1 and E2 upper andlower sections of the conveying device FE. Each module M1 and M2 has, ineach plane E1 and E2, in each case two metal bearing plates AB, on whichsorting containers SB can be lined up closely side by side. It can beseen that the conveyable-article carriers FT on the transportingcarriages TW circulate above the sorting containers SB such that, uponactuation of the detent pawl SK (see FIG. 1), the conveyable articles(not illustrated specifically in FIG. 3) can be ejected into a sortingcontainer SB assigned to the respective coding.

FIG. 2 shows closer details of the conveying device FE illustrated inFIG. 3. In the cross section illustrated here, it can be seen that thetransporting carriage TW is guided, via rollers designated by R, on twotubular profiles or tubes P extending in the transporting direction TR(see FIG. 1). In this arrangement, the profiles P, aligned parallel toone another at a vertical distance, are connected to one another, inrectilinear regions of the conveying device FE, via webs ST likewiseextending in the transporting direction TR, said webs ST being dispensedwith in the curved regions. A transporting carriage TW is driven via anendlessly circulating transporting cable TS, on which the transportingcarriage TW is fastened with the aid of a driver MN. On the side locatedopposite the transporting cable TS, the transporting carriage TW has ametal supporting plate TB on which the individual conveyable-articlecarriers FT are fastened by the end side and which also bears the detentpawls SK and the associated solenoids HM. The metal supporting plate TBfunctions in this arrangement as a securing means for the pivot pins DAof the movable wall parts BW, while the fixed wall parts FW of theindividual conveyable-article carriers FT are connected fixedly to themetal supporting plate TB via end-side flanges F (see FIG. 1).

FIGS. 4 and 5 show a side view and a plan view, respectively, of asorting apparatus made up of individual modules M. In this arrangement,the individual modules N correspond to the modules M1 and M2 illustratedin FIG. 3, but, in FIG. 4, an additional feed belt ZB, which is arrangedbeneath the bottom plane E1 and is intended for providing empty sortingcontainers SB, is also illustrated. Upon removal of a full sortingcontainer SB from the plane E1 or the plane E2, said sorting containercan then be replaced by an empty sorting container SB provided on thefeed belt ZB.

In the illustration according to FIGS. 4 and 5, a vertical deflection HUin located on the left-hand side in front of the first module M, whilean end-side input module EM adjoins the last module M on the right-handside. It can be seen that, in the region of said input module EM, theindividual conveyable-article carriers FT can be loaded from the rear,from the end side or from the front, it being possible for loading to becarried out manually or mechanically.

FIG. 6 shows a vastly simplified schematic illustration of the guidanceof the conveying device FE (see FIGS. 2 and 3) over the two planes E1and E2. The line L shows the spatial routing of the transporting cableTS (see FIG. 4), the transporting direction being indicated by arrowsTR. The guidance of the transporting cable TS in the region of thevertical deflection HU is indicated by two interengaging wheel rims RK1and RK2. In order to simplify the illustration, the guidance of thetransporting cable TS in the region of the input module EM is indicatedby deflection rollers U. In the case of the actual embodiment, however,use in made here of a cable wheel in the plane E1 and of a wheel rim inthe plane E2. In this cane, the cable wheel in the plane E1 servessimultaneously as a drive for the conveying device FE as a whole (seeFIG. 2). The spatial routing of the profiles P (see FIG. 2) parallel tothe line L cannot be seen in FIG. 6.

FIG. 7 shows a vastly simplified schematic illustration of the verticaldeflection HU according to FIG. 6 in detail. It can be seen that thetransporting cable TS arrives in the transporting direction TR, fromright to left, on the rear side of the top plane E2 or upper section,via the wheel rim RK1 obliquely forwards into the front side of thebottom plane E1 or lower section and, from there, continues in thetransporting direction TR, from left to right. As it progresses, thetransporting cable TS then arrives in the transporting direction TR,from right to left, on the rear side of the bottom plane E1 or lowersection and is deflected, via the wheel rim RK2, obliquely forwards intothe front side of the top plane E2 or the upper section and thencontinues in the transporting direction TR, from left to right. Forpurposes of clarity, the left ends of the upper and lower sections ofthe conveying device FE are referred to as the first ends and the rightends of the upper and lower sections of the conveying device (not shownin FIG. 7; see FIG. 6) are referred to as the second ends.

The routing of the profiles P (see FIG. 2) is not illustrated in FIG. 7.The profiles P, which are necessary for guiding the transportingcarriages TW (see FIG. 2) over the second wheel rim RK2 likewise runthrough the interior of the first wheel rim RK1. The diameters of thetwo interengaging wheel rims RK1 and RK2 in this arrangement areselected such that the transporting carriages TW, along with theconveyable-article carriers FT fitted thereon (see FIG. 2), can runthrough the interior of the wheel rim RK1 without obstruction.

FIG. 8 shows a plan view of the wheel rim RK1, which has its innercircumference mounted rotatably on a total of ten supporting rollers SR.In this arrangement, in each case five supporting rollers SR,distributed over a quarter-circle, are arranged on carriers TG which,for their part, are fastened on the machine framework (not illustratedspecifically) such that they can be adjusted via slots LL.

FIG. 9 shows a radial section through the wheel rim RK1 and a carrierroller TR, which is arranged rotatably, via a ball bearing KL, on aspindle Z of the carrier TG.

The section illustrated in FIG. 9 also shows that the carrying cable TSin guided over an insert E of the wheel rim RK1. Quiet running isconsiderably improved as a result, in particular the drivers MN for thetransporting carriages TW (see FIG. 2) being guided over the rubberinsert E without rattling.

It can be seen from FIG. 8 that, in terms of the service life of thetransporting cable TS which can be expected, guidance of thetransporting cable TS over the wheel rim RK1 can be equated withguidance over a centrally mounted cable wheel. On the other hand, thearrangement which is illustrated in FIG. 8 has the advantage that thesecond wheel rim RR2 (see FIG. 7) as well as the profiles P and thetransporting carriages TW with the conveyable-article carriers FT (seeFIG. 2) can be guided through the first wheel rim RK1.

From the above description, it is apparent that the objects of thepresent invention have been achieved. While only certain embodimentshave been set forth, alternative embodiments and various modificationswill be apparent from the above description to those skilled in the art.These and other alternatives are considered equivalents and within thespirit and scope of the present invention.

What is claimed is:
 1. A sorting apparatus comprising:a conveying deviceincluding an upper section and a lower section, the upper and lowersections being connected by a transport carriage, the transport carriagebeing connected to an endless cable, the transport carriage also beingconnected to a plurality of article carriers, the transport carriage andendless cable circulating the article carriers from the upper section tothe lower section, the endless cable extending around a first wheel asthe cable proceeds from the upper section to the lower section, thecable extending around a second wheel as the cable proceeds from thelower section to the upper section, each wheel having an innercircumference rotatably mounted onto a plurality of supporting rollers.2. The sorting apparatus of claim 1 wherein the first wheel extendsthrough the second wheel.
 3. The sorting apparatus of claim 2 wherein atleast one of the two wheels is separable so said one of the two wheelscan be removed from the other of the two wheels.
 4. The sortingapparatus of claim 1 wherein the wheels comprise non-metallic insertsfor engaging the cable.
 5. The sorting apparatus of claim 4 wherein theinserts consist of rubber.
 6. The sorting apparatus of claim 1 whereinthe upper and lower sections are disposed parallel to one another, eachsection comprising a front side disposed between a first and secondopposing ends thereof and a rear side disposed between said first andsecond opposing ends, the front sides of the upper and lower sectionsbeing substantially coplanar, the rear sides of the upper and lowersections being substantially coplanar,the first wheel being disposedbetween the first ends of the upper and lower sections and extendingfrom the rear side of the upper section to the front side of the lowersection, the second wheel being disposed between the first ends of theupper and lower sections and extending from the rear side of the lowersection to the front side of the upper section.
 7. The sorting apparatusof claim 6 wherein the endless cable is propelled from the second end ofthe upper section along the rear side thereof to the first end of theupper section, around the first wheel to the first end of the lowersection at the front side thereof, along the front side of the lowersection to the second end thereof, around at least one deflection rollerdisposed at the second end of the lower section to the rear side of thelower section, along the rear side of the lower section from the secondend to the first end thereof, around the second wheel to the front sideof the upper section at the first end thereof, along the front side ofthe upper section to the second end thereof and around at least onedeflection roller disposed at the second end of the upper section to therear side of the upper section.
 8. The sorting apparatus of claim 1wherein the transport carriage comprises a plurality of rollers, theupper and lower sections of the conveying device each comprise a tubularmember that engages the rollers of the transport carriage.
 9. A sortingapparatus comprising:a conveying device including an upper section and alower section, the upper and lower sections being connected by atransport carriage, the transport carriage being connected to an endlesscable, the endless cable being propelled by a transport roller, thetransport carriage being connected to a plurality of article carriers,the transport carriage and endless cable circulating the articlecarriers from the upper section to the lower section, the upper andlower sections being disposed parallel to one another, each sectioncomprising a front side disposed between a first and second opposingends thereof and a rear side disposed between said first and secondopposing ends, the front sides of the upper and lower sections beingsubstantially coplanar, the rear sides of the upper and lower sectionsbeing substantially coplanar, the first ends of the upper and lowersections engaging a first wheel that extends from the rear side of theupper section to the front side of the lower section, the first ends ofthe upper and lower sections engaging a second wheel that extends fromthe rear side of the lower section to the front side of the uppersection, the endless cable extending around the first wheel as the cableproceeds from the rear side of the upper section to the front side ofthe lower section, the cable extending around the second wheel as thecable proceeds from the rear side of the lower section to the front sideof the upper section, each wheel having an inner circumference rotatablymounted onto a plurality of supporting rollers.
 10. The sortingapparatus of claim 9 wherein the first wheel extends through the secondwheel.
 11. The sorting apparatus of claim 10 wherein at least one of thetwo wheels is separable so said one of the two wheels can be removedfrom the other of the two wheels.
 12. The sorting apparatus of claim 9wherein the wheels comprise non-metallic inserts for engaging the cable.13. The sorting apparatus of claim 12 wherein the inserts consist ofrubber.
 14. The sorting apparatus of claim 9 wherein the endless cableis propelled from the second end of the upper section along the rearside thereof to the first end of the upper section, around the firstwheel to the first end of the lower section at the front side thereof,along the front side of the lower section to the second end thereof,around at least one deflection roller disposed at the second end of thelower section to the rear side of the lower section, along the rear sideof the lower section from the second end to the first end thereof,around the second wheel to the front side of the upper section at thefirst end thereof, along the front side of the upper section to thesecond end thereof and around at least one deflection roller disposed atthe second end of the upper section to the rear side of the uppersection.
 15. The sorting apparatus of claim 9 wherein the transportcarriage comprises a plurality of rollers, the upper and lower sectionsof the conveying device each comprise a tubular member that engages therollers of the transport carriage.
 16. A sorting apparatus comprising:aconveying device including an upper section and a lower section, theupper and lower sections being connected by a transport carriage, thetransport carriage being connected to an endless cable, the endlesscable being propelled by a transport roller, the transport carriagebeing connected to a plurality of article carriers, the transportcarriage and endless cable circulating the article carriers from theupper section to the lower section, the transport carriage comprises aplurality of rollers, the upper and lower sections of the conveyingdevice each comprise a tubular member that engages the rollers of thetransport carriage, the upper and lower sections being disposed parallelto one another, each section comprising a front side disposed between afirst and second opposing ends thereof and a rear side disposed betweensaid first and second opposing ends, the front sides of the upper andlower sections being substantially coplanar, the rear sides of the upperand lower sections being substantially coplanar, the first ends of theupper and lower sections engaging a first wheel that extends from therear side of the upper section to the front side of the lower section,the first ends of the upper and lower sections engaging a second wheelthat extends from the rear side of the lower section to the front sideof the upper section, the endless cable extending around the first wheelas the cable proceeds from the rear side of the upper section to thefront side of the lower section, the cable extending around the secondwheel as the cable proceeds from the rear side of the lower section tothe front side of the upper section, each wheel having an innercircumference rotatably mounted onto a plurality of supporting rollers,the first wheel extending through the second wheel, the wheels eachcomprising non-metallic inserts for engaging the cable.
 17. The sortingapparatus of claim 16 wherein at least one of the two wheels isseparable so said one of the two wheels can be removed from the other ofthe two wheels.
 18. The sorting apparatus of claim 16 wherein theinserts consist of rubber.
 19. The sorting apparatus of claim 16 whereinthe endless cable is propelled from the second end of the upper sectionalong the rear side thereof to the first end of the upper section,around the first wheel to the first end of the lower section at thefront side thereof, along the front side of the lower section to thesecond end thereof, around at least one deflection roller disposed atthe second end of the lower section to the rear side of the lowersection, along the rear side of the lower section from the second end tothe first end thereof, around the second wheel to the front side of theupper section at the first end thereof, along the front side of theupper section to the second end thereof and around at least onedeflection roller disposed at the second end of the upper section to therear side of the upper section.